Valve Spring Collar Weight Reduction via Composite Additive Manufacturing

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Solution Overview

Problem

Existing valve spring collars for internal combustion engines are not optimized for dynamic use, leading to high masses and reduced engine dynamics, which limits the achievable engine rotational speed.

Innovation Solution

A valve spring collar with a plate-shaped main body and at least one cavity, produced using additive methods, reducing weight and allowing for increased dynamics, combined with reinforcing elements to prevent sagging, and subtractive processing for precise configuration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If a conventional valve spring collar design is used, then the structural strength is sufficient, but the mass is high which reduces engine dynamics

Engineering Contradiction:

Improvemass of valve spring collarVSAvoidstructural strength

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The valve spring collar is divided into multiple segments or layers with different material properties. The inner layer uses a softer material (e.g., aluminum alloy) while the outer layer uses a harder material (e.g., steel), creating a composite structure that optimizes both weight and strength characteristics

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The valve spring collar employs composite materials with different mechanical properties in different regions. The combination of softer inner material and harder outer material creates a structure that reduces overall mass while maintaining sufficient structural strength through the synergistic properties of the composite construction

Inventive Principle:

Principle #40Composite materials

2Speed

If the valve spring collar mass is reduced for higher engine rotational speed, then engine dynamics improve, but the collar may sag under spring forces

Engineering Contradiction:

Improveengine rotational speedVSAvoidstructural stability

Core Design Contradiction:

SpeedVSStability of the object's composition

Solution Approach 1:

The multi-material composite structure allows the valve spring collar to achieve optimal mass reduction for high-speed operation while the harder outer material provides the necessary stiffness and strength to prevent sagging under closing spring forces during dynamic operation

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

Different regions of the valve spring collar are assigned different material qualities - the outer layer uses harder material specifically where structural stability and resistance to deformation are critical, while the inner layer uses softer material to reduce overall mass, creating localized optimization of properties

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS10794241B2Reduced-weight value spring collar

Publication Date: 2020.10.06 DR ING H C F PORSCHE AG

AI summary

A valve spring collar (10) for supporting spring forces of closing springs (40) that act on gas exchange valves (32) in an internal combustion engine has a plate-shaped main body (12). A through opening (14) leads through the main body (12) for receiving and attaching a valve stem (36) of the gas exchange valve (32). The valve spring collar (10) also has at least one cavity (16). A method for producing the valve spring collar (10) includes at least one additive production method step.